T90 Cluster Gear Thrust Washer Help

[Daves43GPW]

Hello All,

I started working on assembling my T90 today and ran into a slight problem. The thrust washer that rides against the case on the small end of the cluster gear (part 640411) has a tab that should engage on a shoulder in the transmission case to prevent this washer from turning. It appears someone was previously in my transmission and ground the shoulder on the case down such that the washer now turns with the cluster gear. Has anybody ran into this issue before? Any suggestions?

Another question I have is on the end play of the cluster gear assembly. The service manual states there should be .012-.018" of end play on the cluster gear. I haven't yet figured out a way to put my dial indicator on the shaft but it doesn't feel like there is any end play in the assembly. I installed a NOS cluster gear from Ron Fitzpatrick Jeep Parts and the thrust washers and bearings are from the Novak master rebuild kit. Should I take this apart and lightly sand down the steel washer?

Regards,

David

[specialty]

Have you looked under tech tips? If not not click on the jeep above and click tech tips. Scroll down  you will find a good article on rebuilding the T-90. The author says he could never find much useful information in the service manual so maybe this will help you out or steer you in the right direction. Good luck

Ron

[Daves43GPW]

I have been closely following the Rick Stivers rebuild guide as posted in the tech section. He does note it is not uncommon to see less then .005" end play so I'm not really concerned there. Worst case I can do what Novak suggests and lightly sand the steel thrust washer to get the end play back in spec. My main concern is the steel thrust washer is spinning. It appears Willys intended this washer to be the wear surface. If this part is spinning the transmission case would be subjected to wear. At the moment the best solution I can think of is seeing if a local shop can braze a small tab in place to act as a shoulder.

[specialty]

That may be your only possibility. If you have a mig welder put you a good spot of weld there and take a Dremel tool and form it possibly. I have had good luck welding cast with a mig. Makes some splatter so be sure to protect the surrounding surfaces if you go that route.

Ron